Panel type laminated wallboard partition



Nov. 18, 1952 G. w. BAKER PANEL TYPE LAMINATED WALLBOARD PARTITION 2 SHEETSSHEET 2 Filed July 2, 1946 Nov. 18, 1952' e. 'w. BAKER PANEL TYPE LAMINATED WALLBOARD PARTITION Filed July 2, 1946 2 SHEETSSHEET 1 I INVENTOR.

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be treated, a very great disadvantage.

Patented Nov. 18, 1952 PANEL TYPE LAMINATED VVALLBOARD PARTITION George William Baker, Chicago Heights, 111., assignor to United States Gypsum Company, Chicago, Ill., a corporation of Illinois Application July 2, 1946, Serial No. 681,116

4 Claims.

This invention relates to wall board partitions particularly those made by laminating plaster board into panels and joining these panels toether in a novel manner to form non-loadbearing partitions.

It has been found in certain types of construction that a considerable savings in space can be obtained if partitions are made only 2" thick instead of the usual /2". In the case of large apartmentbuildings this apparently small saving which greatly hindered their commercial applications; such for example as (1) owing to excessive weight of a 2 thickness of gypsum board the units to be erected must be relatively small resulting in a great number of joints which must (2) Conduits, pipes, fittings, etc., could not be installed without requiring patching of the areas through which the pipes, etc., have been installed. This is a decided disadvantage as the patchin of such areas is expensive. (3) No good'low cost system of joining the boards at the top and bottom and to each other has been found.

It has been discovered that all of the disadvantages of the prior art can be overcome by following the principle set forth in this invention, which will be subsequently described so that anyone skilled in the art in which this invention is a part can practice it without the exercise of inventive ability.

It is therefore the object of this invention to disclose a type of construction which will enable gypsum boards to be erected into solid partitions with a minimum amount of joints and other areas to be treated upon the surface before decorating.

It is also an object of this invention to provide a solid gypsum board partition which can be relatively easily erected in the field by the ordinary trade mechanic without the use of special tools.

It is a further object of this invention to provide a new method of joining gypsum board and anchoring them to the ceiling and floor to form a solid partition with materials already available upon the market.

It is a still further object of this invention to provide a thin partition which can be erected and put to use immediately without requiring extensive drying time.

Various other objects of this invention will readily occur to those skilled in the art of which this invention is a part.

In carrying out this invention gypsum boards are laminated together in a novel manner to give a solid non-loadbearing partition. Briefly the invention consists of erecting two offset laminated partition units together, by means of special clips, upon opposite sides of an angle or T sheetmetal runner in such a manner so as'to form. a panel with a tongue and groove type of edge for joining adjacent panels together edge to edge. The laminated partition units are formed by securing together two wall boards, preferably gypsum boards, in offset relation. This is usually done in a factory, though it can also be done on the job. The units are the same but are erected back to back in such a manner as to give an inversely congruent relation. To further aid in securing the partition units together, sheetmetal screws are passed through the unit into the sheetmetal runners sandwiched in between. The appropriate size hole is previously punched in the sheetmetal to aid in attaching the screws.

Conduits,pipes, etc., are placed inside the partition Without marring the exterior surface by cutting away the inside laminae of the two units, which are to be in parallel relation to each other before joining them together. a

After erecting the trim can be installed such as by fastening to the sheetmetal member with longer sheetmetal screws and the wall decorated in the usual manner.

This invention is best understood by means of the following drawings which are given by way of illustration and not by way of limitation. These drawings should be referred to in order to obtain a clearer understanding of this invention.

Figure 1 illustrates how the various units are erected to form panels and the panels joined together with a continuous U-shaped retaining member to form a partition.

Figure 2 is similar to Figure 1 except that one unit has not been applied in order to show the position of the floor and ceiling runners with respect to the boards and also the use of an adhesive.

Figure 3 shows a clip used to join two units together to form a panel.

Figure 3A is an enlarged view of the angular runner shown in Figure 2.

Figure 4 illustrates a T type of floor or ceiling runner.

Figure 4A shows how a T runner can be formed from an angle.

Figure 5 is a section of a portion of a panel near the edge showing the way the clip holds the two units together to form a panel and the joining of adjacent panels together.

Figure 6 is a section through the partition showing how the trim can be secured to the runner.

Figure 7 is a section through the partition near the ceiling illustrating a means of anchoring the partition thereto.

In the drawings like numbers designate the same element of the partition in each figure. In the figures, l are laminated gypsum board units made by laminating two or more sheets of gypsum boards together in offset relation as shown to give a shiplap edge. These units, which are alike, are applied back to back in such a manner that they are in inversely congruent relation with each other and spaced upon opposite sides of an angle or T-shaped runner marked 2 and 3 upon the drawings. These runners are attached to the floor and ceiling. The angle and T runners are shown in Figures 3A, 4 and 4A.

By erecting the units in this manner panels 4 are formed which have tongue and groove edges. In order to hold the units against each other U-shaped clips or retainin members 5 and 1 are placed on the groove side of the panel in such a manner that the projecting portions of the clips extend between the laminae of the adjoining gypsum board units, see Figures 1, 2, and 5. An adhesive layer 6 can be applied between the units to further secure them together. The panels are also attached to the runners by means of the sheetmetal screws 8 such as shown in Figures 1, 2, and 7. The next panel is formed by fitting the tongue forming part of the units into the groove of the adjoining panel on each side of the runner and then securing the units together as described above, see Figure 5. This operation is repeated until the entire partition is erected.

When it is desired to partition off a structure the ceiling and floor runners are attached in the exact location of the partition. These runners, preferably an angle, are made from sheet metal such as 22 gauge black or galvanized steel sheets bent into the desired shape. While an angle is desired, a T-shape runner such as shown in Figures 4 and 4A can also be used; these can be formed by spot welding sheets together but preferably formed by struckout bent in both directions as shown in Figure 4A. These runners are attached by means of nails or screws and besides acting as runners they can also be used to form T and L type of joints formed between intersecting partitions as well as to secure door bucks and window frames to the partition. The runners are secured to the adjacent partition or frame so that the projectin leg of the angle or member is in about the center of the intersection and the adjoining partition is secured thereto by being placed a-straddle the projecting portion of the runner. Shee-tmetal screws are passed through the pan-e1 and the runner to hold the two oppositely spaced wallboard units together. These units, which are formed from offset laminated wallboards or substantially equal Width are placed in inversely congruent relation. These oppositely spaced units form panels with tongue and groove edges. In order to hold the groove portion in place U- shaped retaining members 5 or 1 are inserted into the groove of the panel with the leg portion of the channel beingin-serted into the joint between the adhered wallb-oard forming the adjacent units such as previously described. However, the edge of the units is placed upon opposite sides of the vertical runner to form an L or T type partition. In order that the units will bear properly against the adjacent wall that edge is made square instead of offset.

The panels are preferably formed from gypsum boards made by inclosing a layer of set calcined gypsum between paper liners. The method of manufacturing board from calcined gypsum is well known. Patents which describe how such boards can be made are 1,034,746; 1,029,328; 1,383,249; 1,330,413; 1,540,045; 2,079,338 and 2,079,565. While other sheetlike material can be used to form the partition such for example as those made from fibrous materials and sold as insulation board, hardboard and also asbestos cement sheets, a gypsum board is preferred in practicing this invention as it is well suited for the purpose. It is important that the sheets be such that they can be adhered to each other and that the U-shaped clip .can penetrate between the laminae and that the board be stiff and strong and easily sawn. A gypsum board is ideally suited for this purpose.

The clip 5 need not necessarily be of the shape as shown though the one disclosed is preferred as it can be cheaply made, is readily inserted in between the laminae, has a wide bearing surface and does not interfere with the joining of the panels together along their edges. A wide range of dimensions are possible. A wire type clip can also be used. This can be of the same shape and dimensions as the clip shown in Figure 3. It is desirable however to sharpen the end which is to be driven between the lamination. In other words the clip would be like a large staple. The preferred material for making the clip is about 20 gauge black or galvanized steel sheets. The clips are usually spaced about 18 inches apart. However the clip can be continuous such as shown as I in Figure 1 for all or practically all of the way. The cross section of the continuous clip can be the same as that shown in Figure 3 but instead of being about an inch wide it can be larger and extend the entire length of the edge. The edges of the member penetrating into the space between the boards need not be pointed.

It is desirable sometimes to use an adhesive to adhere the two units together along with the clip. This is however not necessary as the clip gives sufficient holding power. If an adhesive is used it can be applied to the back of one or both panels before erecting. Such adhesive as described in patent application Serial Number 496,074, now issued as Patent Number 2,518,281 to Thomas P. Camp and Chester N. Kalmodin, and using a mixture of emulsified asphalt and partially dextrinized starch, preferably that referred to as KB paste which is ground hot roll flaked steamed comminuted corn, has been found very satisfactory. A wide range of proportions can be used such as between substantially about 3 to 25 parts of asphalt to 8 to 20 parts KB paste. Very good results have been obtained with a ratio of 2 parts by weight of KB paste to 1 of emulsified asphalt. A powder type of adhesive made from calcined gypsum and cold water .soluble animal lue mixed with water as well as various other glues made from casein, soya beans, dextrine, rubber compositions or the like can also be used.

It will be found more expedient to cut openings 2| in the units for electrical outlet boxes and the like before erecting. The notching of the back of the laminaof each unit for electrical conduits and pipes for plumbing, and the like, broadly referred to as service conduits, obviously must be done before the units are erected. The notching can be done with a portable saw and a chisel or any other means which may occur to those skilled in the art. Some care is required to make sure that the notched areas coincide and are in the proper location. It is not advisable to remove too large a portion as the partition will be unnecessarily weakened.

The openings for doors and Windows are out out of the entire partition and a steel or wooden frame installed. In order to anchor the units adjoining the door bucks or window frames thereto it'is necessary to attach a T or angle sheetmetal runner to the frame and to secure the units to these runners with sheetmetal screws or the like as previously described. The portion of the steel frame forming the casing is reinforced with wood in order to provide a greater bearing surface. This is particularly necessary with steel door bucks because of the excessive force exerted upon the casing when the door is slammed shut. It is always desirable to place one or two screws 8 into each-panel into the top and bottom runners in order to further secure them in place. In applying the sheetmetal screws a punch is used to form a hole in the gypsum board and in the sheetmetal. The size of the hole is sufficient to enable the screws to penetrate and to provide good holding power to the sheetmetal member. The size of the hole is controlled by the size of the screw.

The head of the screws can be covered with a joint or other type cement. All joints between panels and at corners can be treated the same as is commonly practiced in the wall board art. This usually calls for the application of a reinforcing tape to the corners or other joints in order to prevent cracks from forming followed by the application of a plastic material to hide the joint and tape to give a smooth appearing wall when decorated.

In certain situations it may be found desirable to join two panels together which do not have a tongue and groove or other interlocking edge. The edges may be square. This can be accomplished by placing a sheetmetal strip between the units and spanning the joint and adhering the units to this strip with a sheetmetal screw. This strip can extend the entire length of the joint between the panels. All joints and corners are covered with tape over which is applied a plastic cement trowelled to form a smooth surface.

After the partition has been erected it is ready for the trim is which can also be secured to the partition by sheet metal screws [6 adhered to sheetmetal runners or the like, such as shown in Figure 6.

From the above description it is evident that there are three methods used in securing the units to each other to form the panel (1) by placing a sheetmetal member such as from an angle or T runner or flat sheets between the units and securing the units on both sides to the sheetmetal with sheetmetal screws or the like, (2) applying clips such as those which are U-shaped on'the groove edge of the panel which is imbedded into the laminae and inserting the tongue edge into the corresponding groove of the adjoining panel and (3) applying an adhesive layer in between the two units. units in place is the use of moulding along the ceiling and floor.

It is important that all the sheets forming the lamination, which makes the unit, be of one material which preferably should be gypsum board as the strength, uniformity of thickness; and other properties of this material are outstandingly better. These sheetsforming the units can be stapled as well as glued together. Gluing is preferred as it does not leave an area upon the outside which must be covered.

While sheetmetal, preferably steel, is the material of choice in forming the runners for anchoring the partition to the structure to be partitioned and in securing the wall board units together, other materials which can conveniently be inserted between the units and secured thereto can be used, such for example as plastics, treated paper, and the like. The gauge of the sheetmetal can also be varied between wide limits but 22 gauge steel metal sheets have been found the best. If zinc, aluminum or copper are used a heavier gauge is more desirable.

The above examples are given for the purpose of disclosing a full, clear, concise and exact description of the invention so as to enable any person skilled in the art of which this invention is a part to carry out the invention Without the exercise of no more than the ordinary skill. Various modifications and alterations will readily occur to those skilled in the art to which this invention appertains without the exercise of inventive ability.

By way of summary this invention comprises a solid partition structure made from laminated units of preferably gypsum board in offset relation applied to each side of sheetmetal floor and ceiling runners or flat sheets in inversely congruent relation so as to give a tongue and groove or other type of interlocking edge between the panels formed by the paired units. The units are held together at least at one edge by U- shaped or similar clips which are imbedded into the area between the laminae of each unit. Adhesives can also be used to supplement the clips in holding the units together. The joining of the partition units to each other and to other members as well as to-frames for doors and windows is obtained by attaching angle or T-shaped sheetmetal members to the object to which the partition is to be anchored and then applying the laminated units to each side followed by the insertion of screws through the units into the sheetmetal. The method of bonding units together by using a sheetmetal member such as a leg of an angle or portion of a Tor a flat sheet in between the units and then passing sheetmetal or other screws through the units into the sheetmetal is an important part of this invention. Conduits, pipes, etc. are embedded in the partition by removing the inside portion of each unit in the vicinity of the object to be inserted.

Having disclosed a practical embodiment of this invention and specific examples and uses which are given to insure a clear understanding of the essence of this invention, it is not the intention to be limited thereby for, obviously, many variations may be made by those skilled in the A further aid in anchoring the v art-and still be within the scope of thisinvention which is only limited in extent by the forthcoming claims.

I claim:

1. A process of erecting a non-loadbearing laminated wallboard partition comprising securing a horizontally placed runner to the surface of the structure to be partitioned, adhering two wallboards of substantially equal width together in offset relation to form a wallboard unit with shiplap lateral edges, applying a pair of said units to said runner in edge to edge and back to back and inversely congruent relation to form a panel with tongue and groove vertical edges, securing the groove edges of said pair of laminated wallboard units forming said panel together by inserting prongs of 'U-shaped clips in the joints between the laminae of each of said wallboard units whereby the inner lamina of each unit is secured to the other and securing together the other vertical edges of said inner laminae forming the tongue of said panel by inserting said other edges into the groove of an adjacent simlaminated wallboard partition claimed in claim 1, with the added step of further securing said pair of units in back to back relation with an adhesive.

3. The process of erecting the non-loadbearin laminated wallboard partition claimed in claim 1, .in which said runner has an angular crosssection and includes a vertical leg and said units are applied upon opposite sides of said leg of said runner.

4. A. process of erecting a non-loadbearing laminated wallboard partition comprising securing a horizontally placed runner to the surface of the structure to be partitioned, adhering two wallboards of substantially equal width together in offset relation to form a wallboard unit with shiplap lateral edges, applying a pair of said units to said runner in edge to edge and back to back and inversely congruent relation to form a panel with tongue and groove vertical edges, securing the groove edges of said pair of laminated wallboard units forming said panel together by inserting the legs of a continuous U-shaped retaining member defining an elongated channel and extending a substantial distance along said groove in the joints between the laminae of each of said wallboard units whereby the inner lamina of each. unit is secured to the other and securing together the other vertical edges of said inner laminae forming the tongue of said panel by inserting said other edges into the groove of an adjacent similar panel.

GEORGE WILLIAM BAKER.

REFERENCES CITED The following references are of record in the file of this patent:

UNITED STATES PATENTS Number Name Date 604,698 Kuhne May 24, 1898 1,134,736 Gleason Apr. 6, 1915 1,578,344 Munroe Mar. 30, 1926 1,595,673 Magney et a1 Aug. 10, 1926 1,657,332 Absmeier Jan. 24, 1928 1,753,487 Vaaler Apr. 8, 1930 1,955,515 Reed Apr. 17, 1934 1,980,900 Bemis Nov. 13, 1934 1,985,196 Tashjian Dec. 18, 1934 1,987,828 Horn Jan. 15, 1935 2,141,888 Venzie Dec. 27, 1938 2,173,094 Burson Sept. 19, 1939 2,258,909 Reens Oct. 14, 1941 2,389,573 Balduf Nov. 20, 1945 2,399,978 Bartholomew May 7, 1946 2,404,307 OConnor July 23, 1946 FOREIGN PATENTS Number Country Date 4,590 Germany of 1879 179,840 Great Britain of 1922 764,426 France of 1934 541,733 Great Britain of 1941 

